Volkswagen New Beetle. Manual - part 1459

 

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Volkswagen New Beetle. Manual - part 1459

 

 

Fig. 8: Removing Union Nut With 3217 Wrench 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Pull fuel delivery unit and seal out of opening in fuel tank.  

Installing 

Installing the fuel delivery unit is carried out in the reverse order. 

NOTE:

If the delivery unit is to be replaced then drain old delivery unit before disposal.

NOTE:

z

When inserting the fuel delivery unit make sure that the fuel gauge sensor 
is not bent.  

z

Insert flange seal of fuel delivery unit into the fuel tank opening in dry 
condition.  

z

Only coat with fuel when installing fuel delivery unit flange.  

z

Ensure fuel hoses are seated securely.  

z

Secure fuel hoses with spring-type clamps.  

z

Note installation position of fuel delivery unit flange: the marking on flange 
must align with marking on fuel tank -arrows-. 

Fig. 9: Aligning Marking On Flange With Marking On Fuel Tank 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel System - New Beetle, 1.8L (APH, AWV & AWP)

  

z

Perform work sequence "Procedure after voltage supply open circuit". 

See Procedure After Correcting Voltage Supply Open Circuit . 

z

Check DTC memory and read readiness code: 

See Diagnostic Trouble Code (DTC) Memory, Checking And Erasing . 

z

Match engine electronics control module to throttle valve control module: 

See Engine Control Module (ECM) To Throttle Valve Control Module, Adapting . 

FUEL GAUGE SENSOR, REMOVING AND INSTALLING 

Removing 

z

Remove fuel delivery unit. See RULES OF CLEANLINESS .  

z

Release and pull off terminals for wires -3- and -4-. 

Fig. 10: Pulling Off Terminals For Wires -3- And -4- 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Lift retaining tabs -1- and -2- with a screwdriver and pull fuel gauge sensor out downward -arrows-.  

Installing 

z

Insert fuel gauge sensor in guides on fuel delivery unit and push up until it engages.  

FUEL TANK, REMOVING AND INSTALLING 

Special tools and equipment 

Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

After installing fuel delivery unit, check that the supply, return and vent 
pipes are still clipped onto fuel tank.  

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel System - New Beetle, 1.8L (APH, AWV & AWP)

  

z

VAG 1383 A Engine/transmission jack 

Fig. 11: Identifying VAG 1383 Engine/Transmission Jack 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

VAG 1331 Toque wrench (5-50 N.m) 

Fig. 12: Identifying VAG 1331 Toque Wrench (5-50 N.m) 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

Removing 

z

Note safety precautions before starting work. See SAFETY PRECAUTIONS WHEN WORKING ON 
FUEL SUPPLY SYSTEM
 .  

z

First check whether a coded radio is installed. If so, obtain anti-theft coding.  

z

With ignition switched off disconnect battery Ground strap.  

z

Open fuel flap.  

z

Remove rear right wheel housing liner. 

See REAR WHEEL HOUSINGS LINER, ASSEMBLY OVERVIEW 

z

Remove rear axle. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel System - New Beetle, 1.8L (APH, AWV & AWP)

  

See AXLE BEAM 

z

Drain fuel tank and clean fuel filler neck and surrounding area.  

z

Unscrew securing bolts and remove tank flap unit with rubber cup.  

z

Remove securing bolt on filler neck.  

z

Fold rear seat bench forward.  

z

Remove fuel gauge sensor cover plate and disconnect connector.  

z

Remove cover from under fuel tank. 

z

Disconnect return hose -2- (blue), supply hose -1- (black) and breather hose -3- (white) at connecting 
point. 

Fig. 13: Disconnecting Return Hose, Supply Hose And Breather Hose At Connecting Point 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

z

Remove tensioning strap. When doing this support fuel tank with engine/transmission jack VAG 1383 A. 

z

Lower fuel tank.  

Installing 

Installation is carried out in the reverse order; when doing this note the following: 

z

Breather hoses are to be installed kink-free.  

z

Fuel hoses are to be installed kink-free. 

WARNING:

Fuel supply hoses are under pressure! Before removing from hose 
connection wrap a cloth around the connection. Then release 
pressure by carefully pulling hose off connection.

NOTE:

Press buttons on hose couplings to do this.

 

2003 Volkswagen New Beetle GLS 

1998-2004 ENGINE Fuel System - New Beetle, 1.8L (APH, AWV & AWP)

  

 

 

 

 

 

 

 

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